Composite joinery

ABSTRACT

A horizontal joint between upper and lower building panels, as well as a building wall including such a horizontal joint, in which a liquid diverting arrangement includes a gutter with first and second ends and at least one aperture disposed between these ends. Also contemplated are a method and apparatus for forming at least two building panels, in which the panels have different reveal dimensions, and a method and apparatus for forming a building panel in which a first reveal portion is registered while a second reveal portion has been formed at a preselected distance therefrom. Further contemplated are a method and kit for customizably assembling a building wall, in which panels having different thickness dimensions can be interchangeably connected with one another, as well as a method and kit for customizably assembling a building wall, in which on or more decorative profile panels and one or more structural building wall panels can be interchangeably connected with one another.

FIELD OF THE INVENTION

[0001] The present invention relates generally to joint arrangementsand, more particularly, to composite, external panel joints forbuildings.

BACKGROUND OF THE INVENTION

[0002] Generally, at a typical horizontal or vertical joint, two panelsmeet. Each panel typically includes one or more liners that encase ahomogenous core, such as a foam core. It is also known to provide eachpanel with one or more “male” or “female” connecting portions, eachconfigured to accommodate respective “female” or “male” connectingportions of the other panel.

[0003] In the context of horizontal joints, an internal gutter may beincluded in order to accommodate liquid that has bypassed the joint. Oneway to drain the liquid is via the provision of vertical channelsbetween horizontally adjacent panels. Such gutters also often typicallyserve as effective media for equalizing pressure within the horizontaljoint in question. U.S. Pat. No. 5,749,282, to Brow et al. discloses aconventional horizontal joint having these features.

[0004] U.S. Pat. No. 3,740,909 (Stinnes), appears to disclose anarrangement for affording drainage from a panel. Particularly, Stinnesshows an arrangement of grooves 45 (see FIG. 5) that appear to attend tothe problem of internal drainage. However, a highly complicatedstructure is provided, with a highly unique application.

[0005] In the context of horizontal joints between vertically adjacenthorizontal panels, a need has thus been recognized in connection withproviding effective and efficient drainage from an internal gutter,while avoiding the use of complicated and potentially costly structuresfor that purpose.

[0006] An independent need has also been recognized in the context ofboth horizontal and vertical joints, in connection with providing areveal that is deeper than the norm, both for aesthetic purposes and, inat least some instances, easier installation.

[0007] Further, a need has also been recognized in connection withfacilitating the customizable manufacture of horizontal or verticalpanels with reveals.

[0008] Finally, but not necessarily exclusively, a need has also beenrecognized in connection with affording the facilitated customization ofbuilding wall assemblies, having horizontal and/or vertical panels, inwhich an insulative panel, such as one including structural foam, caneasily be juxtaposed with simple profile panels (e.g., formed from sheetmetal) in a desired predetermined arrangement.

SUMMARY OF THE INVENTION

[0009] The present invention contemplates, in accordance with at leastone presently preferred embodiment, an arrangement in which at least oneaperture is provided over a predetermined horizontal extent of aninternal gutter of a horizontal joint. Thus, any liquid collected in theinternal gutter may drain outwardly through the aperture(s) in thegutter, rather than, or in addition to, being fed to vertical channels.

[0010] The present invention also contemplates, in accordance with atleast one presently preferred embodiment, a reveal (i.e., an inwardrecess into at least one of the upper and lower panels) that isconsiderably deeper than the norm, conceivably two or three times asdeep. The advantages include eased bending in corner panels and the factthat unsightly repairs can be concealed in the back of the reveal. Ifone or more apertures, as described above, is provided, such a deepreveal can provide for an easy drainage path for liquid exiting theaperture(s). A sloped drainage shelf may be provided as part of thereveal, in order to assist drainage.

[0011] Further, another concept contemplated by at least one presentlypreferred embodiment of the present invention is the customization ofhorizontal joints to have any of a variety of reveal sizes or types. Forexample, the reveal can be changed in size so that, for example, revealsizes from ⅛″to 2″are attainable in ¼″increments.

[0012] Another concept contemplated by at least one presently preferredembodiment of the present invention is the selective, customizablejuxtaposition of insulative panels, such as those including structuralfoam, with simple profile panels in a desired predetermined arrangement.Unique connective media are preferably provided for this purpose.

[0013] Generally, at least one presently preferred embodiment of thepresent invention broadly contemplates a horizontal joint between upperand lower building panels, wherein: the lower panel comprises at leastone connector comprising at least one of: at least one male connectorand at least one female connector; the upper panel comprises at leastone connector comprising at least one of: at least one male connectorand at least one female connector; at least one connector of the upperpanel being connected with at least one connector of the lower panel toform an outer joint; an arrangement for diverting liquid; the liquiddiverting arrangement comprising a gutter; the gutter having first andsecond ends; the liquid diverting arrangement further comprising atleast one aperture disposed between the first and second ends of thegutter.

[0014] Further, at least one presently preferred embodiment of thepresent invention broadly contemplates a building wall comprising: anupper building panel and a lower building panel; the lower panelcomprises at least one connector comprising at least one of: at leastone male connector and at least one female connector; the upper panelcomprises at least one connector comprising at least one of: at leastone male connector and at least one female connector; at least oneconnector of the upper panel being connected with at least one connectorof the lower panel to form an outer joint; an arrangement for divertingliquid; the liquid diverting arrangement comprising a gutter; the gutterhaving first and second ends; the liquid diverting arrangement furthercomprising at least one aperture disposed between the first and secondends of the gutter.

[0015] Additionally, at least one presently preferred embodiment of thepresent invention broadly contemplates joint between two buildingpanels, comprising a reveal having a depth that is no less than about0.75 inch.

[0016] Further, at least one presently preferred embodiment of thepresent invention broadly contemplates a method of forming at least twobuilding panels, the method comprising the steps of: providing apparatusfor forming building panels; forming a first panel with the apparatus;forming a second panel with the apparatus; the forming of the firstpanel comprising the formation of at least a portion of a first reveal;and the forming of the second panel comprising the formation of at leasta portion of a second reveal; wherein the first and second revealscomprise different dimensions.

[0017] Moreover, at least one presently preferred embodiment of thepresent invention broadly contemplates apparatus for forming at leasttwo building panels, the apparatus comprising: an arrangement forforming first and second panels; the panel forming arrangementcomprising an arrangement for forming at least a portion of a firstreveal in the first panel and at least a portion of a second reveal inthe second panel; the reveal forming arrangement comprising anarrangement for imparting different dimensions to the first and secondreveals.

[0018] Furthermore, at least one presently preferred embodiment of thepresent invention broadly contemplates a method of forming a buildingpanel, the method comprising the steps of: forming a first portion of areveal in the building panel; forming a second portion of the reveal ata preselectably variable distance with respect to the first portion; andthereafter registering the first portion of the reveal.

[0019] Additionally, at least one presently preferred embodiment of thepresent invention broadly contemplates apparatus for forming a buildingpanel, the apparatus comprising: an arrangement for forming a firstportion of a reveal in the building panel; an arrangement forming asecond portion of the reveal at a preselectably variable distance withrespect to the first portion; and an arrangement for registering thefirst portion of the reveal.

[0020] Further, at least one presently preferred embodiment of thepresent invention broadly contemplates method of customizably assemblinga building wall, the method comprising the steps of: providing at leastone panel having a first thickness dimension; providing at least onepanel having a second thickness dimension, the second dimension beingdifferent from the first dimension; and effecting at least oneconnection between a panel having the first thickness dimension and apanel having the second thickness dimension; wherein at least one of: apanel having the first thickness dimension and a panel having the secondthickness dimension comprises an arrangement for interchangeablyconnecting with a panel having the first thickness dimension and a panelhaving the second thickness dimension.

[0021] Additionally, at least one presently preferred embodiment of thepresent invention broadly contemplates a kit for customizably assemblinga building wall, the kit comprising: at least one panel having a firstthickness dimension; and at least one panel having a second thicknessdimension, the second dimension being different from the firstdimension; wherein at least one of: a panel having the first thicknessdimension and a panel having the second thickness dimension comprises anarrangement for interchangeably connecting with a panel having the firstthickness dimension and a panel having the second thickness dimension.

[0022] Further, at least one presently preferred embodiment of thepresent invention broadly contemplates a method of customizablyassembling a building wall, the method comprising the steps of:providing at least one panel of a first type; providing at least onepanel of a second type; effecting at least one connection between apanel of the first type and a panel of the second type; the at least onepanel of the first type comprising a structural building wall panel; theat least one panel of the second type comprising a decorative profilepanel; at least one of: the building wall panel and the decorativeprofile panel comprising an arrangement for interchangeably connectingwith a panel of the first type and a panel of the second type.

[0023] Finally, but not necessarily exclusively, at least one presentlypreferred embodiment of the present invention broadly contemplates a kitfor customizably assembling a building wall, the kit comprising: atleast one panel of a first type; at least one panel of a second type;the at least one panel of the first type comprising a structuralbuilding wall panel; the at least one panel of the second typecomprising a decorative profile panel; at least one of: the buildingwall panel and the decorative profile panel comprising an arrangementfor interchangeably connecting with a panel of the first type and apanel of the second type.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is a fragmentary isometric view illustrating an exteriorwall structure in a conventional horizontal panel application;

[0025]FIG. 2 is a broken cross-sectional view, taken along the line 2-2of FIG. 1, illustrating a conventional insulated building panel;

[0026]FIG. 3 is a cross-sectional view, taken along the line 3-3 of FIG.1, illustrating a conventional horizontal joint.

[0027]FIG. 4 is a cross-sectional view illustrating an insulatedbuilding panel according to the present invention;

[0028]FIG. 4a is a perspective, isolated view of a face sheet and gutterhaving one type of aperture disposed therein;

[0029]FIG. 4b is substantially the same view as FIG. 4a but illustratinganother type of aperture;

[0030]FIG. 4c is substantially the same view as FIG. 4a but illustratingyet another type of aperture;

[0031]FIG. 4d is substantially the same view of FIG. 3, but illustratingan aperture arrangement through the structural foam core;

[0032]FIG. 5 is substantially the same view as FIG. 4, but illustratinga “mid-hook” face sheet attachment;

[0033]FIG. 6 is substantially the same view as FIG. 4, but illustratinga narrower reveal width;

[0034]FIG. 7 is substantially the same view as FIGS. 4 and 7, butshowing a greater reveal width;

[0035]FIG. 8 is substantially the same view as FIG. 4, but illustratingan upper panel of greater depth than the lower panel;

[0036]FIG. 9 is substantially the same view as FIG. 4, but illustratinga lower panel of greater depth than the upper panel;

[0037]FIG. 10 is substantially the same view as FIG. 4, but illustratingupper and lower panels of greater depth than those shown in FIG. 4;

[0038]FIG. 11 is substantially the same view as FIG. 4, but illustratinga reveal of customizably varying width;

[0039]FIG. 11A illustrates a conventional registration block arrangementused in the formation of building panels;

[0040]FIG. 11B illustrates a registration block arrangement inaccordance with an embodiment of the present invention;

[0041]FIG. 12 illustrates a building wall portion that includes bothfoam panels and profiled sheet metal panels;

[0042]FIG. 13 is a close-up cross-sectional view taken from FIG. 12, andillustrating a connection between a profiled panel and a foam panel;

[0043]FIG. 14 is a close-up cross-sectional view taken from FIG. 12, andillustrating a connection between two profiled panels; and

[0044]FIG. 15 is a close-up cross-sectional view taken from FIG. 12, andillustrating a connection between two foam panels.

DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0045] FIGS. 1-3, and the accompanying disclosure herebelow, are takenfrom U.S. Pat. No. 5,749,282 (Brow et al.) for the purpose ofillustrating conventional horizontal joinery, and associated components,having aspects that might be utilized in accordance with at least onepresently preferred embodiment of the present invention. The same patentis fully incorporated by reference into this specification, in orderthat further conventional details forming the background and/orenvironment of at least one presently preferred embodiment of thepresent invention may be relied upon as needed.

[0046] Referring to FIG. 1, there is illustrated an exterior wallstructure 10 supported on a structural framework including verticalcolumns 12. The wall structure 10 is assembled from individual panels 14having adjacent panel ends 16, 18 forming a vertical joint 20 and beingconnected along the lower and upper side edges 22, 24 to form horizontalwall joint 26.

[0047] Referring to FIG. 2, the insulated building panel 14 comprisesinner and outer facing sheets 28, 30 and a structural foam core 32filling the interior space of the building panel 14 and adhesivelyconnecting the facing sheets 28, 30 to provide a structural panel. Atthe upper edge 22 of the building panel 14, the inner and outer facingsheets 28, 30 provide inner and outer male connectors or tongues 34, 36.At the lower edge 24 of the panel 14, the inner and outer facing sheets28, 30 provide inner and outer female connectors 38, 40 adapted toreceive the tongues 34, 36 of a subjacent building panel. As isillustrated FIG. 3, the inner and outer female connectors 38, 40 eachreceive a bead 42, 44 of sealant, such as a non-hardening butyl sealant.The beads 42, 44 of sealant are adapted to be penetrated by the tongues34, 36 of a subjacent panel to form inner and outer seals as shown inFIG. 3.

[0048] In accordance with the present invention, gutter means 45 isprovided at the upper edge 22 of the building panel 14 and intermediateof the inner and outer tongues 34, 36. The gutter means extendssubstantially entirely along the full length of the building panel 14.As will be described, the gutter means serves to eliminate liquidsbypassing the outer joint formed between the female connector 40 and thetongue of 36 of a subjacent building panels. The gutter means 45 has agenerally U-shaped transverse profile including upstanding sides 46, 48and a web of 50 connecting the sides 46, 48. As can be seen in FIG. 2,the side 48 of the gutter means 45 also constitutes a portion of thetongue 36. Therefore, the gutter means 45 is formed, in part, by theouter male connector tongue 36.

[0049] Referring to FIG. 3, there is illustrated a horizontal joint 26between upper and lower panels 14A, 14B. Comparing FIGS. 2 and 3, itwill be observed that the location of the upper edge 22 may be varied,as shown at 22′ and 22″, and thus the width of the horizontal joint 26may be varied as shown at 26′ and 26″. As can be seen in FIGS. 3 and 4,the lower building panel 14 is secured to the column 12 by a clip 56 anda fastener 58. As can be seen in FIG. 3, the clip includes a downturnedcentral flange at 60 penetrating the foam core 32B and engaging theinner facing sheet 28B and a pair of inclined flanges 62, only onevisible in FIG. 3, penetrating the foam core 32B and extending into thetongue 34B. The clip 56 also has a main flange portion 64 which overliesthe upstanding side 46 of the outer facing sheet 30B. The fastener 58extends through the main flange portion 64, the upstanding side 46, thefoam core 32B, the inner facing sheets 28B and into the vertical column12. In this manner, both the inner and outer facing sheets 28B, 30B ofthe panel 14B are secured to the vertical column 12.

[0050] The disclosure now turns to a discussion of various embodimentsof the present invention. In FIGS. 4-7, components that aresubstantially analogous to components in FIGS. 1-3 have been soindicated by advancing the reference numerals by 100.

[0051]FIG. 4 is a cross-sectional view illustrating an insulatedbuilding panel according to at least one presently preferred embodimentof the present invention. In addition to the conventional componentsillustrated in FIGS. 1-3 (whose reference numerals have been advancedhere by 100), also illustrated are thermal break 190, reveal 192,aperture(s) (or weep hole[s]) 194, sloped shelf 196 and edge-hookconnection 198.

[0052] Thermal break 190, indicated with dotted lines at upper panel114A, merely constitutes a gap between outer face sheet 130A (oftentermed simply a “face sheet”) and inner face sheet 128A (often termed a“liner” or “liner sheet”), wherein a portion of the foam core 132A isexposed. A similar thermal break exists on lower panel 114B, notnumbered but indicated with dotted lines between outer face sheet 130Band inner face sheet 128B.

[0053] Although the use of a foam core 132A/132B is discussed herein, itis to be understood that this essentially represents only one type ofcore material that can be utilized in a composite building panel (orstructural panel). For example, other types of core material may besubstituted for the foam core, such as a conventional honeycomb corestructure.

[0054] Indicated at 192 is what is known in the art as a reveal, or, inthe context of a building wall assembly, an indentation that is recessedinto the wall assembly. In the present example, reveal 192 is definedbetween upper panel 114A and lower panel 114B. Generally, a revealprovides an enhanced visual effect on the outer side of a building wallassembly. Conventionally, reveals tend to be shallow, that is, oflimited dimension in a direction defined orthogonally between the outerside of the wall assembly and the inner side. (For the presentdiscussion, “depth” or “thickness” may be defined as that dimensionoriented horizontally with respect to FIG. 4, while the dimensionperpendicular thereto in FIG. 4, oriented vertically, may be defined as“width”.)

[0055] In contrast, the present invention, in accordance with at leastone presently preferred embodiment, broadly contemplates a reveal 192that is considerably deeper than the norm. Surprisingly, it has beenfound that such a reveal provides an enhanced visual effect from theoutside and, further, that it is easier to fabricate and install cornerpanels, and connections therebetween, having such a reveal.Additionally, any repairs that are located within the reveal areessentially hidden to passersby because of the depth of the reveal. Suchrepairs might include, but are not limited to, those that are undertakenwhen forming a corner joint, particularly, when, subsequent to cutting aV-notch in the panels to be used at a corner and bending the panels,plate or sheet material is provided at the seam where the V-notch wascut.

[0056] The depth of the reveal is indicated as the dimension x in FIG.4. In accordance with a presently preferred embodiment of the presentinvention, this dimension will be no less than about 0.75 inch. In theillustrated example, dimension x is 1.25 inches, while the depth of bothpanels 114A and 114B is 2 inches. Surprising and unexpected advantages,as described above, have been encountered with deep reveals. Further,the present invention broadly contemplates reveals having dimensionsthat are even greater than 1.25 inches, as deep as is practicable inview of the physical requirements inherent to the wall assembly inquestion.

[0057] A sloped shelf 196 may preferably be provided within reveal 192.In accordance with at least one presently preferred embodiment of thepresent invention, the shelf 196 will be sloped at about three degrees.Conventionally, slopes of five degrees have been encountered.

[0058] An independent concept is indicated with the arrow designated byreference numeral 194. Particularly, arrow 194 illustrates the presenceof one or more apertures through face sheet 130B, and at the bottom ofgutter 145, through which liquid present in the gutter 145 may exit thegutter 145. One or more such apertures may preferably be distributedthroughout the length (i.e. in a direction perpendicular to the plane ofthe drawing) of gutter 145. For example, one such aperture may bepresent about every 12 inches along the length of gutter 145.Preferably, the location and distribution of the aperture(s) will bechosen in such a manner as to drain liquid from the gutter, and also toequalize pressure within the gutter, most efficiently and effectively.

[0059]FIGS. 4a-4 c illustrate, in isolated perspective view, a lowerpanel face sheet 130B, where this forms gutter 145, with different typesof apertures that might be utilized in accordance with at least onepresently preferred embodiment of the present invention.

[0060]FIG. 4a illustrates a bottom aperture 194 a, which may be disposedin a lowermost or bottom portion of gutter 145.

[0061]FIG. 4b, on the other hand, illustrates an “edge notch” aperture194 b, which may be disposed in a portion of gutter 145 that is awayfrom an end corner 145C of gutter 145.

[0062]FIG. 4c illustrates a “corner notch” aperture 194 c that isdisposed right at an end corner 145C of gutter 145. In this case, itshould be understood that the end corner 145C may essentially be locatedat a corresponding end of the corresponding panel. If the gutter 145does not feed into a vertical discharge channel (see the patent to Browet al.) and instead terminates, at the illustrated end, at a gasket orother solid member that does not permit the onward horizontal flow ofliquid beyond the gutter end, it will be appreciated that the liquidwill then be discharged out through the corner notch 145 c.

[0063] The types of apertures illustrated in FIGS. 4a-4 c are providedas examples only, and are not intended in any way to limit the scope ofthe present invention. In each case, the aperture or apertures inquestion is/are disposed intermediately with respect to the opposingends of the gutter, in contrast or in addition to arrangements in whichthe gutters open at their ends to vertical discharge channels, asdescribed in the patent to Brow et al.

[0064] The present invention also contemplates, in accordance with atleast one presently preferred embodiment, an arrangement in which theone or more apertures being used are not disposed to direct liquid flowfrom what are essentially lowermost portions of gutter 145, asillustrated in FIGS. 4a-4 c, but are disposed at somewhat higher pointsof the gutter wall that faces outwardly. In this case, liquid willaccumulate within the gutter and will discharge from the aperture(s)once the liquid level within the gutter matches the level of theapertures. Although it is generally recognized that such accumulation ofliquid in a gutter is undesirable, it will be appreciated that thepresent invention contemplates such an arrangement particularly inconjunction with the use of vertical discharge channels, as discussed inthe patent to Brow et al. In this instance, it will be appreciated thatthe aperture(s) presently contemplated can serve the purpose of overflowdrainage, in the event that the normal drainage through the gutterend(s) to the vertical discharge channels is backed up or inhibited forany reason.

[0065] It will be appreciated that such a means of egress of liquid fromgutter 145 can be used alone or in conjunction with an arrangement suchas that described in the aforementioned patent to Brow et al., in which,at junctures between horizontally adjacent building panels, there arevertical discharge channels into which an internally disposed gutteropens.

[0066] In accordance with at least one presently preferred embodiment ofthe present invention, a deep reveal 192 may be utilized in conjunctionwith the aperture(s) 194 just described. In such an eventuality, and asillustrated in FIG. 4, the reveal 192 may preferably be defined partlyby a sloped shelf 196. Such a sloped shelf will preferably assistconsiderably in diverting any liquid emanating from apertures 194 out ofthe reveal 192. It will be appreciated that the sloped shelf 196 alsoserves to divert away liquid from external sources, such as rain that isblown into the reveal 192 by the wind that enters reveal 192 by washingdown the external face of the building wall assembly. The shallow slopediscussed heretofore, preferably of about three degrees, has been foundto be quite adequate for affording drainage away from the reveal 192.

[0067] Preferably, reveal 192 will have a predetermined width y. Amanner of customizing this width will be discussed further below. In theembodiment illustrated in FIG. 4, if it is assumed that the overalldepth of the panel structure is about 2 inches, then dimension y, thewidth of the reveal 192, is illustrated as being ½inch, which isrecognized throughout the industry as a standard width.

[0068] As shown in FIG. 4D, it is conceivable, within the scope of thepresent invention, to utilize one or more apertures 194 d in conjunctionwith a panel system such as that described and illustrated heretoforewith respect to FIG. 3. As shown, aperture(s) 194 d may proceed fromgutter means 45B, through foam core 32B, and may exit through an openingin face sheet 30B. It will thus be appreciated that the presentinvention contemplates not only the use of one or more apertures inconjunction with a deep reveal that permits immediate egress of liquidfrom an internal gutter arrangement to the outside, but also inconjunction with a structural panel containing a foam or other core,such as the panel 14B shown in FIG. 4B, wherein aperture(s) 194 d mayactually tunnel through the foam or other core in a suitable manner inorder to facilitate the egress of liquid from an internal gutterarrangement. Again, such an arrangement of aperture(s) could be providedinstead of or in addition to the types of vertical discharge channelsthat are described in the patent to Brow et al.

[0069] Indicated at 198 is an edge-hook, or terminal portion, of outerface sheet 130B. It has been found that forming a face sheet in such amanner provides for a sounder connection with upper panel 114A thanmight otherwise be encountered. However, in an alternative embodiment,FIG. 5 illustrates a “mid-hook” 199 in place of the edge-hook 198 ofFIG. 4. Mid-hook 199, in FIG. 5, is preferably formed as a crimped,intermediate portion of face sheet 130B, configured for extendingupwardly into a corresponding pocket in upper panel 114A.

[0070]FIGS. 6 and 7 represent substantially similar views as FIG. 4, butillustrate, respectively, a narrower reveal width and a greater revealwidth. Particularly, if it is assumed that the overall depth of thepanel structure is about 2 inches in each case, then dimension y, thewidth of the reveal 192, is illustrated as being ⅛inch in FIG. 6 and 2inches in FIG. 7. As will be described further below, the presentinvention contemplates, in accordance with at least one presentlypreferred embodiment, the possibility of customizing dimension y in aunique manner.

[0071] The disclosure now turns to a discussion of a particularlyversatile application afforded by at least one presently preferredembodiment of the present invention. In FIGS. 8-10, components that aresubstantially analogous to components in FIGS. 1-3 have been soindicated by advancing the reference numerals by 200.

[0072]FIG. 8 illustrates an example in which upper panel 214A has anotably greater overall depth (or thickness) z than the overall depth(or thickness) a of lower panel 214B. In the illustrated example,dimension a is equal to about 2 inches while dimension z is equal toabout 2.75 inches. As shown, dimension x is still equal to about 1.25inches.

[0073] On the other hand, FIG. 9 illustrates an example in which upperpanel 214A has a notably smaller overall depth z than the overall deptha of lower panel 214B. In the illustrated example, dimension a is equalto about 2.75 inches while dimension z is equal to about 2 inches. Inthis case, dimension x, or the greatest depth of the reveal, is equal toabout 2 inches. The proportion represented by the greatest reveal depthx with respect to the depth a of the lower panel has thus increased toabout {fraction (8/11)}, or about 0.727.

[0074] Finally, FIG. 10 illustrates an example in which upper panel 214Ahas the same, larger overall depth z as the overall depth a of lowerpanel 214B. In the illustrated example, dimension a is equal to about2.75 inches while dimension z is also equal to about 2.75 inches.Dimension x, or the greatest depth of the reveal, is again equal toabout 2 inches, and the proportion represented by the greatest revealdepth x with respect to the depth a of the lower panel is again{fraction (8/11)}, or 0.727. Accordingly, FIGS. 8-10 illustrate ameasure of versatility, in assembling wall assemblies, afforded by atleast one presently preferred embodiment of the present invention. Ineach case, it is possible to maintain a significantly deep reveal, withthe attendant advantages described heretofore.

[0075] Furthermore, it will be appreciated that essentially the sametype of connection scheme has been preserved in each of theconfigurations illustrated in FIGS. 8-10. As shown, an upper bentportion 298 of lower outer face sheet 230B may preferably be soconfigured and designed as to mate adequately with a correspondingrecessed portion of upper outer face sheet 230A. In this case, the bentportion 298 is in the form of a “J-hook”, but could also be configuredas a “midhook” as shown in FIG. 11. In either case, the presentinvention broadly contemplates, in accordance with at least onepresently preferred embodiment, the facilitated interchangeable assemblyof various upper panels 214A and lower panels 214B of differing depths,whereas conventionally this might have been difficult and cumbersome inview of differing and incompatible connection schemes.

[0076] In accordance with an embodiment of the invention, the “J-hook”298 shown in FIGS. 8-10, and elsewhere, could be realized in twodiscrete pieces, as opposed to the single piece shown. Thus, one smallerpiece would be constituted only by the J-shaped portion. In this manner,the tight 180-degree bend illustrated in FIGS. 8-10 would be eliminated.Such a realization might be desirable if the bulk of the outer facesheet is formed from a heavy-gauge material, and would thus beunsuitable for the type of intricate bending shown in FIGS. 8-10. Insuch an instance, the separate J-hook 298A could be formed from alighter gauge material, such as stainless steel or aluminum. Of course,a separate J-hook might be desirable for other reasons, as determined bythe dictates of the user.

[0077] It will further be appreciated that the configurations describedand illustrated with respect to FIGS. 8-10 can be utilized in thecontext of vertically-oriented panels, as opposed tohorizontally-oriented panels. In the case of vertically-oriented panels,then, it is to be understood that FIGS. 8-10 can be interpreted as plan,rather than elevational, views and that the connection between panels214A and 214B can be construed as a vertical joint, rather than ahorizontal joint. The inclusion of aperture(s) 294 does not necessarilydetract from the use of panels 214A and 214B in a vertical orientation,as they could conceivably assist in serving the purpose of pressureequalization, especially if internal gutter 245 does not lead toorthogonally oriented external channels at either of its ends.

[0078] The disclosure now turns to a discussion of customizing thereveal width in accordance with at least one presently preferredembodiment of the present invention. In FIG. 11, components that aresubstantially analogous to components in to FIGS. 1-3 have been soindicated by advancing the reference numerals by 300.

[0079]FIG. 11 illustrates an arrangement in which the width (i.e., thedimension y shown in earlier drawings) of reveal 392 can be customized.Thus, indicated at 300, via dotted and solid lines, is a representationof drainage shelf 396 in different positions as a function of the widthof reveal 392. Also shown is an optional drip edge 396.

[0080] In accordance with at least one presently preferred embodiment ofthe present invention, suitable tooling may be utilized to quickly andefficiently change over an appropriate forming apparatus, such as aroll-forming apparatus, from one configuration, in which one givenreveal width is produced, to another configuration, in which anothergiven reveal width is produced. It is believed that this type ofversatile customization would be of great benefit to manufacturers whowould wish to cater, at short notice, to the divergent requests of oneor more customers as regards the width of a reveal. In accordance withat least one presently preferred embodiment of the present invention,reveal widths from about ⅛″to greater than about 2″ (such us up to about6″) are possible, such as in increments of about ¼″.

[0081]FIG. 11A illustrates a conventional registration block (or siderail) arrangement typically utilized subsequent to the roll-forming offace sheets for building panels. Typically, registration blocks are usedto hold face sheets in an accurate positional relationship prior to, andduring, the application of an insulative material, such as foam, betweenthe face sheets. As shown, block 402 may include, among other things, afirst end face 404 and a second end face 406. As shown, first end face404 is configured for engaging with that portion 405 a of an inner facesheet 405 (e.g., similar to sheet 328B shown in FIG. 11) that has beenbent at one end of inner face sheet 328B. On the other hand, second endface 406 is configured for engaging with that portion 408 a of an outerface sheet 408 (e.g., similar to sheet 330B shown in FIG. 11) that formsthe lower part of a reveal (such as reveal 392 shown in FIG. 11).

[0082] Per convention, the engagement of a registration block with facesheets takes place once the face sheets have already been roll-formed,or formed in some other manner, for the purpose of positioning andaligning the face sheets with respect to one another in preparation forthe injection or insertion of the desired core material between the facesheets. In the case of a structural foam core, the foam is typicallyinjected into the cavity between the two face sheets (once registeredvia the registration block), and the registration block typicallyassists in preventing the foam from inadvertently leaking from thiscavity during the injection process.

[0083] It will thus be appreciated that registration block 402, inconnection with the conventional example shown in FIG. 11A, providesregistration at two significant points, namely the aforementioned “bend”portion 405 a of an inner face sheet 405 and the lower “reveal” portion408 a of an outer face sheet 408. A disadvantage that has often beenencountered with the type of registration block illustrated in FIG. 11Ais that essentially only one predetermined and fixed reveal width can beaccommodated. Particularly, since that portion of the outer face sheetdefining the lower limit of the reveal is used in registration, thenonly one reveal width, as defined by the formation of the same portionof the outer face sheet, can essentially only be introduced to thecorresponding registration block. In the industry, it is well-known thatsuch registration blocks are expensive items to purchase and install.Thus, the capacity for customizable formation with different revealwidths is severely hampered, as a different registration block isessentially required for each different reveal width that is introduced.

[0084] In contrast, FIG. 11B illustrates a registration arrangement,according to at least one presently preferred embodiment of the presentinvention, that is configured to accept outer face sheets that result indifferent reveal widths.

[0085] As shown in FIG. 11B, a registration block 452 may include afirst face 454 and a second face 456. Similarly to the arrangementdescribed and illustrated with respect to FIG. 11A, the first face 454will preferably be configured as to engage with that portion 455 a of aninner face sheet 455 (e.g., similar to sheet 328B shown in FIG. 11) thathas been bent at one end of inner face sheet 455. In contrast to thearrangement shown in FIG. 11A, however, the second end face 456 ispreferably configured for engaging not with a portion of an outer facesheet 458 (e.g., similar to sheet 330B shown in FIG. 11) that forms thelower part of a reveal (such as reveal 392 shown in FIG. 11), but with aportion 458 a of an outer face sheet 458 that forms a portion of the topof the reveal. It will thus be appreciated that registration block 452provides registration at two significant points that are different fromthe significant points encountered by the registration block 402 shownin FIG. 11A. In accordance with the embodiment shown in FIG. 11B, thesignificant points are the aforementioned “bend” portion 455 a of aninner face sheet 455 and the “upper” reveal portion 458 a of an outerface sheet 458.

[0086] Accordingly, it will be appreciated that, by registering the“upper” reveal portion 458 a of an outer face sheet 458, a great degreeof latitude is afforded in introducing to the registration block 402inner face sheets 455 that have “lower” reveal portions that were formedwith varying dimensions.

[0087] It will also be appreciated that the inventive arrangement shownin FIG. 11B can lend itself admirably to a forming apparatus in which aroll-forming unit and a foam injection unit (or a unit otherwisededicated to the introduction of an insulative material) are included inthe same assembly line, so that sheets that have been roll-formed canprogress automatically to a registration block for the subsequentintroduction of insulative material. In such an integrated assemblyline, by virtue of the use of a registration arrangement such as thatshown in FIG. 11B, it will be possible to change reveal widths quicklyand efficiently, perhaps even on the fly.

[0088] Conventionally, a roll-forming unit and foam-injection (or otherinsulation introduction) unit are separate entities. It is believed thatintegration of the units to date has been hindered by the inherentdifficulties in changing each apparatus between different configurationsfor use with different reveal widths. However, it is believed that theinventive arrangement illustrated in FIG. 11B lends itself easily to anintegrated assembly line, in that the registration block arrangementwill rarely, if ever, need to be changed, even if significantlydifferent reveal widths are produced in the associated roll-formingunit.

[0089] It will further be appreciated that the inventive arrangementshown in FIG. 11B, with its registration points at regions 455 a and 458a of face sheets 455 and 458, respectively, also aids considerably inpreventing the inadvertent escape of foam from the space formed betweenthe face sheets 455 and 458, and in fact has been found to represent amarked improvement as such in comparison with conventional arrangements.

[0090] The disclosure now turns to a discussion of the customizableassembly of different panels in accordance with at least one presentlypreferred embodiment of the present invention. In FIGS. 12-15, anycomponents that might be substantially analogous to components in FIGS.1-3 have not necessarily been advanced by a multiple of 100 as has beendone in FIGS. 4-11.

[0091]FIG. 12 illustrates a general wall assembly 500 having compositestructural panels, such as foam panels, 501 along with decorativeprofile panels 503. Usually, decorative profile panels 503 are formedfrom sheet metal and may contain therewithin some form of insulationand, as shown, may also contain decorative or otherwise aestheticallysignificant features, such as the types of indentations shown in FIG.12.

[0092] Indicated at 513 is a first connection scheme, to be describedand illustrated in more detail with respect to FIG. 13. Likewise, 514indicates a second connection scheme, corresponding to FIG. 14, whilst515 indicates a third connection scheme, corresponding to FIG. 15. Inaccordance with at least one presently preferred embodiment of thepresent invention, these three types of connection schemes are of such anature that they afford the easy and customizable interchanging andintermingling of structural panels 501 and profile panels 503.

[0093] In FIG. 13, a profile panel 503 is connected atop a structuralpanel 501. In known manner, structural panel 501 includes a structuralfoam core that is flanked by outer face sheet (or simply “face sheet”)518 and inner face sheet(or “inner” or “liner sheet”) 519, respectively.Indicated at 520 is a “J-hook” extension of outer face sheet 518. Areveal 522, as shown, may be defined between the upper, profile panel503 and the lower, structural panel 501. A suitable attachment mechanism524, such as a bolt, may be used to hold firmly a clip 526. This clip526 may include legs 528 and 530, the former extending into thestructural foam core 516 and the latter extending upwardly into a nookor bend formed in inner face sheet 519.

[0094] In known manner, a suitable sealant or sealing arrangement 532may be provided between panels 503 and 501. Upper profile panel 503itself preferably contains outer and inner facing (or face) sheets 534and 536, respectively. At the lower end of outer face sheet 534, thereis preferably a bent terminal portion 535 that serves as a receptaclefor the “J-hook” portion 520 of outer face sheet 518 of lower structuralpanel 501. In known manner, a sheet of insulation 538 may preferably beprovided within profile panel 503.

[0095] In FIG. 14, a first profile panel 503 a is connected atop asecond profile panel 503 b. Similar reference numerals, indicatingsimilar components, have been retained from FIG. 13, with the additionof “a” or “b” to indicate components in panels 503 a and 503 b,respectively.

[0096] As shown, the outer face sheet 518 b of lower panel 503 b mayinclude an intricately bent end portion 540 configured for mating withthe lower bent portion 535 of the outer face sheet 518 a of upper panel503 a. A clip 544, attached to insulation sheet 538 b with a suitableattachment device, such as a bolt, 543, may preferably be configured foraccommodating part of bent end portion 540. Also, it may preferably havea splayed upper end, as shown, to accommodate a bent upper portion ofinner face sheet 536 b of lower panel 503 b. Again, a suitable sealantor sealing arrangement 532′ is preferably provided.

[0097] In FIG. 15, a structural panel 501 is connected atop a profilepanel 503. Similar reference numerals, indicating similar components,have been retained from FIG. 13.

[0098] As shown, a clip 546 may preferably be utilized with attachmentdevices (such as bolts) 548 and 550 that extend into and/or throughinsulation sheet 538. An adapter clip 552, extending from the attachmentpoint of attachment device 550 with clip 546, may preferably beconfigured to extend into the recess created by lower bent portion 535of structural panel 501.

[0099] From a review of FIGS. 13-15, it can now be appreciated that anefficient, customizable and interchangeable system of interconnectionhas been afforded. Particularly, very similar schemes of interconnectionmay be utilized between different pairs of panels (i.e.,structural-profile; profile-profile; profile-structural). In accordancewith at least one presently preferred embodiment of the presentinvention, the connectable ends of each of the panels will preferably beconfigured so as to easily and interchangeably accommodate either aprofile panel or a structural panel, at most with only minormodification.

[0100] Conventionally, profile panels have tended to be formed in rathersingular manner at their connectable ends. It will thus be appreciatedthat, in accordance with at least one presently preferred embodiment ofthe present invention, such panels will preferably undergo at their endssuch artificial formation as to be fully integrable with either anotherprofile panel or a structural panel.

[0101] It may thus be appreciated that, in a broad aspect of theinvention, a profile panel is adaptively configured so as to be able tomate with a structural building panel in such a manner as to mimicessentially the same physical characteristics, and associatedadvantages, normally found in a connection between two structuralbuilding panels. Although one specific manner realizing such a featurehas been described and illustrated with respect to FIGS. 13-15, it is tobe understood that the present invention broadly contemplatesessentially any specific manner of realizing the connections between theillustrated panels, with the proviso that similar performancecharacteristics will be achieved as in the case of two interconnectedstructural panels.

[0102] In a particularly advantageous refinement of this embodiment ofthe present invention, the inner face sheets in question, variouslyindicated at 519, 536, 536 a and 536 b, will preferably be realized insuch a manner as to result in the establishment of a consistent barrier,with consistent sealing, against vapor pressure, air infiltration andwater infiltration. Whereas it has generally been conventional toeliminate liner sheets (536, 536 a, 536 b) from profile panels, thepresent invention contemplates the inclusion of such sheets in a mannerthat essentially mimics the manner in which they are realized instructural panels. Thus, it will be appreciated from a review of FIGS.13, 14 and 15 that the upper and lower panels in each case, be theystructural or profile panels, exhibit similar physical and operationalcharacteristics. For example, the liner sheets of the upper and lowerpanels will exhibit coplanarity as in an interconnection betweenstructural panels (see, for example, FIG. 4).

[0103] Advantages are also apparent in the context of sealing.Particularly, a factory-installed seal (e.g., such as indicated at 532and 532′) is normally supplemented, in the context of adjacentstructural panels, by a field-installed seal. The field-installed sealnormally abuts the liner sheets on the building side of the wallassembly, and will normally migrate into cavities between the upper andlower panels so as to “meet” the factory-installed seal. Such a sealingarrangement provides very favorable protection against air, vapor andwater infiltration.

[0104] Because, in accordance with at least one presently preferredembodiment of the present invention, a profile panel will mimic severalcharacteristics of a structural panel, a similar advantage will beencountered here. Particularly, material from a field-installed sealwill preferably migrate into a cavity 533 (as shown in each of FIGS.13-15) between upper and lower panels, resulting in the same advantagesas just described.

[0105] Between the arrangements illustrated in FIGS. 13-15, it will alsobe appreciated that the different types of clip connections used, thatextend either into a foam core 516 or insulation sheet 538/538 b, areeasily interchangeable.

[0106] Yet another advantage can be found in that essentially the sametype of formation tooling, such as roll-form tooling, can be utilized toform the face or liner sheets of structural panels and profile panelsalike.

[0107] If not otherwise stated herein, it is to be understood that anyand all of the building panels, and interconnections, illustrated anddescribed herein may be utilized either in a horizontal configuration orin a vertical configuration. Particularly, it is recognized that thestructures and components described and illustrated herein in connectionwith at least one presently preferred embodiment of the presentinvention are applicable not only to the context of horizontal panelsconnected by horizontal joints but also to the context of verticalpanels connected by vertical joints.

[0108] Provided herebelow is a brief recapitulation of some featuresaccording to at least one presently preferred embodiment of the presentinvention.

[0109] A deep reveal offers several unique features. First, the depth ofreveal allows it to perform as a pressure equalized pocket, possibly inaddition to an internal pressure equalized pocket (such as may beafforded by an internally disposed gutter), while allowing venting ofthe panel, such as along the entire length of the panel. The depth alsocreates a reveal with a bolder aesthetic appearance, which is known tobe preferred by some designers. Also, the deep reveal can be more easilyfabricated into corner panels than shallow reveals. Bent or foldedcorner panels are the most common applications in this regard.

[0110] Essentially the same geometry as in U.S. Pat. No. 5,749,282 (Browet al.) can be used. This allows the interface with the same extrusionsused for panel trim, reveals, and window systems.

[0111] Vertical joints created at the ends of horizontal panels can betreated in several ways. First, they can be filled with opened extrudedgasketry, which will allow water to drain from the enclosed joint pocketto the vertical joint. Second, a solid closed-cell foam gasket can beused to keep water out of the vertical joint.

[0112] The method of joint design as presented will allow the engagementof multiple panel thickness. For example, a thick panel can be engagedto a thin panel and vice versa. This is accomplished by having a commontop edge of panel regardless of thickness. (See FIGS. 8-10).

[0113] The inventive joint can be used in either a horizontal orvertical orientation. This will be helpful in allowing fewerchangeovers.

[0114] If not otherwise stated herein, it may be assumed that allcomponents and/or processes described heretofore may, if appropriate, beconsidered to be interchangeable with similar components and/orprocesses disclosed elsewhere in the specification, unless an expressindication is made to the contrary.

[0115] If not otherwise stated herein, any and all patents, patentpublications, articles and other printed publications discussed ormentioned herein are hereby incorporated by reference as if set forth intheir entirety herein.

[0116] It should be appreciated that the apparatus and method of thepresent invention may be configured and conducted as appropriate for anycontext at hand. The embodiments described above are to be considered inall respects only as illustrative and not restrictive. The scope of theinvention is defined by the following claims rather than the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

1. A horizontal joint between upper and lower building panels, wherein:said lower panel comprises at least one connector comprising at leastone of: at least one male connector and at least one female connector;said upper panel comprises at least one connector comprising at leastone of: at least one male connector and at least one female connector;at least one connector of said upper panel being connected with at leastone connector of said lower panel to form an outer joint; means fordiverting liquid; said liquid diverting means comprising a gutter; saidgutter having first and second ends; said liquid diverting means furthercomprising at least one aperture disposed between said first and secondends of said gutter.
 2. The horizontal joint according to claim 1 ,wherein said at least one aperture for permits the substantiallyimmediate vertical egress of liquid from said gutter.
 3. The horizontaljoint according to claim 1 , wherein said at least one aperturecomprises means for pressure-equalizing said gutter.
 4. The horizontaljoint according to claim 1 , wherein said at least one aperturecomprises at least two apertures.
 5. The horizontal joint according toclaim 4 , wherein said at least two apertures are distributedsubstantially evenly over the length of said gutter.
 6. The horizontaljoint according to claim 1 , wherein said at least one aperture isdisposed at vertically lowermost portions of said gutter.
 7. Thehorizontal joint according to claim 1 , further comprising an openingdisposed at one end of said gutter, said opening comprising means fordirecting fluid to a vertical discharge channel.
 8. The horizontal jointaccording to claim 1 , further comprising a reveal having a depth thatis no less than about 0.75 inch.
 9. The horizontal joint according toclaim 8 , wherein said reveal comprises a sloped drain shelf.
 10. Thehorizontal joint according to claim 9 , wherein said sloped drain shelfhas a slope of about three degrees.
 11. The horizontal joint accordingto claim 1 , wherein said upper and lower panels comprise at least onecomposite building panel.
 12. The horizontal joint according to claim 11, wherein said at least one composite building panel comprises at leastone composite foam building panel.
 13. The horizontal joint according toclaim 1 , wherein said lower panel comprises two male connectors andsaid upper panel comprises two female connectors.
 14. A building wallcomprising: an upper building panel and a lower building panel; saidlower panel comprises at least one connector comprising at least one of:at least one male connector and at least one female connector; saidupper panel comprises at least one connector comprising at least one of:at least one male connector and at least one female connector; at leastone connector of said upper panel being connected with at least oneconnector of said lower panel to form an outer joint; means fordiverting liquid; said liquid diverting means comprising a gutter; saidgutter having first and second ends; said liquid diverting means furthercomprising at least one aperture disposed between said first and secondends of said gutter.
 15. The building wall according to claim 14 ,wherein said at least one aperture for permits the substantiallyimmediate vertical egress of liquid from said gutter.
 16. The buildingwall according to claim 14 , wherein said at least one aperturecomprises means for pressure-equalizing said gutter.
 17. The buildingwall according to claim 14 , wherein said at least one aperturecomprises at least two apertures.
 18. The building wall according toclaim 17 , wherein said at least two apertures are distributedsubstantially evenly over the length of said gutter.
 19. The buildingwall according to claim 14 , wherein said at least one aperture isdisposed at vertically lowermost portions of said gutter.
 20. Thebuilding wall according to claim 1 , further comprising an openingdisposed at one end of said gutter, said opening comprising means fordirecting fluid to a vertical discharge channel.
 21. The building wallaccording to claim 1 , further comprising a reveal having a depth thatis no less than about ⅝of the overall depth of at least one of saidupper panel and said lower panel.
 22. The building wall according toclaim 21 , wherein said reveal comprises a sloped drain shelf.
 23. Thebuilding wall according to claim 22 , wherein said sloped drain shelfhas a slope of about three degrees.
 24. The building wall according toclaim 1 , wherein said upper and lower panels comprise at least onecomposite building panel.
 25. The building wall according to claim 24 ,wherein said at least one composite building panel comprises at leastone composite foam building panel.
 26. The building wall according toclaim 1 , wherein said lower panel comprises two male connectors andsaid upper panel comprises two female connectors.
 27. A joint betweentwo building panels, comprising a reveal having a depth that is no lessthan about 0.75 inch.
 28. The joint according to claim 27 , wherein saidbuilding panels are oriented horizontally.
 29. The joint according toclaim 27 , wherein said building panels are oriented vertically. 30.Method of forming at least two building panels, said method comprisingthe steps of: providing apparatus for forming building panels; forming afirst panel with said apparatus; forming a second panel with saidapparatus; said forming of said first panel comprising the formation ofat least a portion of a first reveal; and said forming of said secondpanel comprising the formation of at least a portion of a second reveal;wherein said first and second reveals comprise different dimensions. 31.The method according to claim 30 , wherein said apparatus comprisesroll-forming apparatus.
 32. The method according to claim 30 , whereinthe different dimensions comprise different reveal widths.
 33. Themethod according to claim 30 , wherein: said forming of said first panelcomprises the step of shaping a first sheet member; said forming of saidsecond panel comprises the step of shaping a second sheet member;subsequent to said formation of at least a portion of a first reveal,said first sheet member is brought into registration at a registrationblock; and subsequent to said formation of at least a portion of asecond reveal, said second sheet member is brought into registration atthe same registration block as was the first sheet member.
 34. Themethod according to claim 33 , wherein at least one of said registrationsteps is followed by the introduction of an insulative material.
 35. Themethod according to claim 34 , wherein said insulative materialcomprises foam.
 36. The method according to claim 35 , wherein saidintroduction step comprises the injection of said foam into a cavitybound at least by one of said first and second sheet members and anotherphysical boundary.
 37. Apparatus for forming at least two buildingpanels, said apparatus comprising: means for forming first and secondpanels; said panel forming means comprising means for forming at least aportion of a first reveal in said first panel and at least a portion ofa second reveal in said second panel; said reveal forming meanscomprising means for imparting different dimensions to said first andsecond reveals.
 38. The apparatus according to claim 37 , wherein saidpanel forming means comprises roll-forming apparatus.
 39. The apparatusaccording to claim 37 , wherein the different dimensions comprisedifferent reveal widths.
 40. The apparatus according to claim 37 ,further comprising: a registration block; said panel forming meanscomprising means for forming said first panel via shaping a first sheetmember and for forming said second panel via shaping a second sheetmember; said registration block comprising: means for registering saidfirst sheet member subsequent to said first sheet member being shaped;and means for registering said second sheet member subsequent to saidsecond sheet member being shaped.
 41. The apparatus according to claim40 , further comprising means for introducing an insulative materialsubsequent to the registering of at least one of said first and secondsheet members by said registering means.
 42. The apparatus according toclaim 41 , wherein said insulative material comprises foam.
 43. Theapparatus according to claim 42 , further comprising means forintroducing said foam into a cavity bound at least by one of said firstand second sheet members and another physical boundary.
 44. Method offorming a building panel, said method comprising the steps of: forming afirst portion of a reveal in said building panel; forming a secondportion of said reveal at a preselectably variable distance with respectto said first portion; and thereafter registering said first portion ofsaid reveal.
 45. The method according to claim 44 , wherein saidregistering is carried out in preparation for the introduction of aninsulative material.
 46. Apparatus for forming a building panel, saidapparatus comprising: means for forming a first portion of a reveal insaid building panel; means forming a second portion of said reveal at apreselectably variable distance with respect to said first portion; andmeans for registering said first portion of said reveal.
 47. Theapparatus according to claim 46 , further comprising means forintroducing an insulative material subsequent to the registering of saidfirst portion of said reveal.
 48. Method of customizably assembling abuilding wall, said method comprising the steps of: providing at leastone panel having a first thickness dimension; providing at least onepanel having a second thickness dimension, said second dimension beingdifferent from said first dimension; and effecting at least oneconnection between a panel having said first thickness dimension and apanel having said second thickness dimension; wherein at least one of: apanel having said first thickness dimension and a panel having saidsecond thickness dimension comprises means for interchangeablyconnecting with a panel having said first thickness dimension and apanel having said second thickness dimension.
 49. The method accordingto claim 48 , wherein a panel having said first thickness dimension anda panel having said second thickness dimension each comprise means forinterchangeably connecting with a panel having said first thicknessdimension and a panel having said second thickness dimension.
 50. A kitfor customizably assembling a building wall, said kit comprising: atleast one panel having a first thickness dimension; and at least onepanel having a second thickness dimension, said second dimension beingdifferent from said first dimension; wherein at least one of: a panelhaving said first thickness dimension and a panel having said secondthickness dimension comprises means for interchangeably connecting witha panel having said first thickness dimension and a panel having saidsecond thickness dimension.
 51. The kit according to claim 50 , whereina panel having said first thickness dimension and a panel having saidsecond thickness dimension each comprise means for interchangeablyconnecting with a panel having said first thickness dimension and apanel having said second thickness dimension.
 52. Method of customizablyassembling a building wall, said method comprising the steps of:providing at least one panel of a first type; providing at least onepanel of a second type; effecting at least one connection between apanel of said first type and a panel of said second type; said at leastone panel of said first type comprising a structural building wallpanel; said at least one panel of said second type comprising adecorative profile panel; at least one of: said building wall panel andsaid decorative profile panel comprising means for interchangeablyconnecting with a panel of said first type and a panel of said secondtype.
 53. The method according to claim 52 , wherein said building wallpanel and said decorative profile panel each comprise means forinterchangeably connecting with a panel of said first type and a panelof said second type.
 54. The method according to claim 53 , wherein saidconnecting means of said decorative profile panel is configuredsubstantially similarly to said connecting means of said building wallpanel.
 55. The method according to claim 52 , wherein said structuralbuilding wall panel comprises a structural foam core.
 56. A kit forcustomizably assembling a building wall, said kit comprising: at leastone panel of a first type; at least one panel of a second type; said atleast one panel of said first type comprising a structural building wallpanel; said at least one panel of said second type comprising adecorative profile panel; at least one of: said building wall panel andsaid decorative profile panel comprising means for interchangeablyconnecting with a panel of said first type and a panel of said secondtype.
 57. The kit according to claim 56 , wherein said building wallpanel and said decorative profile panel each comprise means forinterchangeably connecting with a panel of said first type and a panelof said second type.
 58. The kit according to claim 56 , wherein saidconnecting means of said decorative profile panel is configuredsubstantially similarly to said connecting means of said building wallpanel.
 59. The kit according to claim 56 , wherein said structuralbuilding wall panel comprises a structural foam core.